Conveyor Belt with Alignment Features

ABSTRACT

A conveyor belt includes a first link having a first protrusion with a first mating surface that is curved. The first protrusion is disposed proximate a first rod receiving aperture of the first link. The belt also includes a second link having a second protrusion with a second mating surface that is curved. The second protrusion is disposed proximate a second rod receiving aperture of the second link. The first mating surface receives and abuts the second mating surface. The second link is restrained against movement in less than three orthogonal directions relative to the first link due to abutment of the first and second mating surfaces. The first and second rod receiving apertures are aligned when the first and second mating surfaces abut. Additionally, the belt includes a connecting rod extending through the first and second rod receiving apertures.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of co-pending application Ser. No.13/311,754, filed Dec. 6, 2011, the disclosure of which is herebyincorporated by reference in its entirety.

FIELD OF THE INVENTION

The embodiments herein are directed to modular conveyor belts and, moreparticularly, to conveyor belt link structures having alignment featuresand methods of assembling such conveyor belts.

BACKGROUND

Conveyor belts are widely used today in a variety of industrialapplications. For example, conveyor belts are used for material handlingand processing applications, as well as a variety of food processingsystems.

Since conveyor belt use is widespread, an economical and efficient wayof manufacturing conveyor belts is necessary to meet this growingdemand. One type of belt provided to increase cost-effectiveness andinstallation efficiencies are modular belts. Modular conveyor belts aremade from many individual links, or belt segments, that are connectedtogether to form a conveyor belt having a desired total length. In orderto assemble a modular conveyor belt, the modular links are carefullyaligned in relation to one another so that a connecting rod can beinserted into rod receiving apertures that extend through the modularlinks. Typically, each modular link has a rod receiving aperture throughwhich a connecting rod may be inserted. However, before the connectingrod can be inserted, the rod receiving aperture in a first modular linkneeds to be aligned with the rod receiving aperture in a second modularlink so that the connecting rod may be inserted through both links. Thisprocess is repeated for each link until all the modular links are heldin place in relation to one another to form a complete conveyor belt.

In some circumstances, aligning two adjacent modular links in order toinsert the connecting rod through the rod receiving apertures in thelinks may be an arduous and time-consuming process. In some cases, itmay be time intensive to carefully position two adjacent links so thatthe rod may be properly inserted. One reason this may be difficult isthat the belt components may be flexible due to an elongated length.Another factor that may contribute to the flexibility of the beltcomponents is the material that the belt components are formed of.Plastic belt links can sometimes be more flexible than metal links.Similarly, the connecting rod may also be flexible, particularly when aplastic rod is used and/or when the belt is particularly wide,necessitating the use of a relatively long rod.

The present disclosure is directed to improvements in alignment andassembly of modular conveyor belt components.

SUMMARY

In one aspect, the present disclosure is directed to a conveyor belt.The conveyor belt may include a first link having a first protrusionextending a first distance from a surface of the first link. The firstprotrusion may include a first mating surface. The first protrusion isdisposed proximate a first rod receiving aperture extending through thefirst link. In addition the conveyor belt may include a second linkhaving a second protrusion extending a second distance from a surface ofthe second link. The second protrusion may include a second matingsurface, wherein the second protrusion is disposed proximate a secondrod receiving aperture extending through the second link. The firstmating surface of the first protrusion may be disposed in a matingrelationship with the second mating surface of the second protrusion.Further, the conveyor belt may include a connecting rod extendingthrough the first rod receiving aperture of the first link and thesecond rod receiving aperture of the second link.

In another aspect, the present disclosure is directed to a modularconveyor belt. The conveyor belt may include a first link having a firstrod receiving aperture and a first protrusion extending a first distancefrom a surface of the link. A first mating surface of the firstprotrusion may be located a predetermined distance from the first rodreceiving aperture. In addition, the first mating surface of the firstprotrusion may be configured to abut a portion of a second linkincluding a second rod receiving aperture. When the first protrusionabuts the portion of the second link, the first rod receiving aperturemay be substantially aligned with the second rod receiving aperture toform a rod receiving path.

In another aspect, the present disclosure is directed to a method ofassembling a conveyor belt. The method may include providing a firstlink having a first protrusion, wherein the first protrusion ispositioned proximate a first rod receiving aperture extending throughthe first link, wherein the first protrusion extends a first distancefrom a first surface of a first leg of the first link, and wherein thefirst protrusion has a first mating surface extending away from thefirst surface. The method may also include providing a second linkhaving a second protrusion, wherein the second protrusion is positionedproximate a second rod receiving aperture extending through the secondlink, wherein the second protrusion extends a second distance from asecond surface of a second leg of the second link, and wherein thesecond protrusion has a second mating surface extending away from thesecond surface. In addition, the method may include aligning the firstreceiving aperture with the second rod receiving aperture by moving thefirst link toward the second link until the first mating surface of thefirst protrusion abuts the second mating surface of the secondprotrusion.

In another aspect, the present disclosure is directed to a conveyorbelt. The conveyor belt may include a first link having a recess in asurface of the first link, wherein the recess includes a first matingsurface, and wherein the recess is disposed proximate a first rodreceiving aperture extending through the first link. In addition, theconveyor belt may include a second link having a protrusion extending asecond distance from a surface of the second link. The protrusion mayinclude a second mating surface, wherein the protrusion is disposedproximate a second rod receiving aperture extending through the secondlink. When the protrusion is engaged with the recess, the first matingsurface of the recess abuts the second mating surface of the protrusion.

In another aspect, the present disclosure is directed to a modularconveyor belt. The conveyor belt may include a first link having a firstrod receiving aperture and a frangible tab extending from a surface ofthe first link. The frangible tab may include a first mating surfacelocated a predetermined distance from the first rod receiving aperture.The first mating surface of the frangible tab may be configured to abuta portion of a second link including a second rod receiving aperture. Inaddition, when the first protrusion abuts the portion of the secondlink, the first rod receiving aperture may be substantially aligned withthe second rod receiving aperture to form a rod receiving path.

In another aspect, the present disclosure is directed to a method ofassembling a modular conveyor belt. The method may include providing afirst link having a first rod receiving aperture and a frangible tabextending from a surface of the first link, the frangible tab includinga first mating surface located a predetermined distance from the firstrod receiving aperture. The method may also include providing a secondlink including a second rod receiving aperture. In addition, the methodmay include abutting a portion of the second link against the firstmating surface of the frangible tab, thereby causing the first rodreceiving aperture to be substantially aligned with the second rodreceiving aperture to form a rod receiving path.

In another aspect, the present disclosure is directed to a modularconveyor belt. The conveyor belt may include a first link having a firstrod receiving aperture and a receiving member disposed at apredetermined distance from the first rod receiving aperture. Thereceiving member may include a first mating surface. In addition, theconveyor belt may include a second link having a second rod receivingaperture and a longitudinally oriented frangible tab extending from asurface of the second link. The frangible tab may include a secondmating surface located a predetermined distance from the second rodreceiving aperture. The receiving member may be configured to receivethe frangible tab. In addition, when the frangible tab is receivedwithin the receiving member, the first rod receiving aperture may besubstantially aligned with the second rod receiving aperture to form arod receiving path.

In another aspect, the present disclosure is directed to a method ofassembling a modular conveyor belt. The method may include providing afirst link having a first rod receiving aperture and a receiving memberdisposed at a predetermined distance from the first rod receivingaperture, the receiving member including a first mating surface. Themethod may also include providing a second link having a second rodreceiving aperture and a longitudinally oriented frangible tab extendingfrom a surface of the second link, the frangible tab including a secondmating surface located a predetermined distance from the second rodreceiving aperture. In addition, the method may include associating thefirst link with the second link such that the frangible tab of thesecond link is received within the receiving member of the first linkand the first mating surface of the first link is abutting the secondmating surface of the second link, thereby substantially aligning thefirst rod receiving aperture with the second rod receiving aperture toform a rod receiving path.

In another aspect, the present disclosure is directed to conveyor belt.The conveyor belt may include a first link having a first matingsurface, wherein the first mating surface is disposed proximate a firstrod receiving aperture extending through at least a portion of the firstlink. The conveyor belt may also include a second link having a secondmating surface, wherein the second mating surface is disposed proximatea second rod receiving aperture extending through at least a portion ofthe second link, wherein the first mating surface is disposed in amating relationship with the second mating surface, and wherein, whenthe first mating surface abuts the second mating surface, the first rodreceiving aperture is substantially aligned with the second rodreceiving aperture to form a rod receiving path.

In another aspect, a conveyor belt is disclosed that includes a firstlink having a first protrusion extending a first distance from a firstsurface of the first link. The first protrusion includes a first matingsurface, and the first mating surface is curved. The first protrusion isdisposed proximate a first rod receiving aperture extending through thefirst link. The conveyor belt also includes a second link having asecond protrusion extending a second distance from a second surface ofthe second link. The second protrusion includes a second mating surface,and the second mating surface is curved. The second protrusion isdisposed proximate a second rod receiving aperture extending through thesecond link. The first mating surface of the first protrusion receivesand abuts the second mating surface of the second protrusion. The secondlink is restrained against movement in less than three orthogonaldirections relative to the first link due to abutment of the firstmating surface and the second mating surface. The first rod receivingaperture and the second rod receiving aperture are aligned when thefirst mating surface abuts the second mating surface. Additionally, theconveyor belt includes a connecting rod extending through the first rodreceiving aperture of the first link and the second rod receivingaperture of the second link.

In another aspect, a conveyor belt is disclosed that includes a firstlink that is at least partially U-shaped to be at least partiallydefined by a first leg, a second leg, and a first connecting portionextending between the first leg and the second leg of the first link.The first link further includes a first rod receiving aperture. Theconveyor belt also includes a second link that is at least partiallyU-shaped to be at least partially defined by a third leg, a fourth leg,and a second connecting portion extending between the third leg and thefourth leg of the second link. The second link further includes a secondrod receiving aperture. Moreover, the conveyor belt includes aconnecting rod extending through the first rod receiving aperture of thefirst link and the second rod receiving aperture of the second link toconnect the first link and the second link. The first link and thesecond link are configured for movement in a longitudinal direction. Thefirst link includes a first protrusion extending from a first surface ofthe first link. The first protrusion includes a first mating surface,and the first mating surface is curved. The first mating surface of thefirst protrusion receives and abuts a second surface of the second linkto limit movement of the second link toward the first link in thelongitudinal direction. The first mating surface of the first protrusionreceives and abuts the second surface of the second link to align thefirst and second rod receiving apertures.

In another aspect, a conveyor belt is disclosed that includes a firstlink having a first protrusion extending a first distance from a firstsurface of the first link. The first protrusion includes a first matingsurface, and the first mating surface is curved. The first protrusion isdisposed proximate a first rod receiving aperture extending through thefirst link. The conveyor belt also includes a second link having asecond protrusion extending a second distance from a second surface ofthe second link. The second protrusion includes a second mating surface,and the second mating surface is curved. The second protrusion isdisposed proximate a second rod receiving aperture extending through thesecond link. The second mating surface and the first mating surface abutto align the first rod receiving aperture and the second rod receivingaperture. The second mating surface and the first mating surface havecorresponding curvature. The second link is restrained against movementin less than three orthogonal directions relative to the first link dueto abutment of the first mating surface and the second mating surface.The conveyor belt additionally includes a connecting rod extendingthrough the first rod receiving aperture of the first link and thesecond rod receiving aperture of the second link.

Other systems, methods, features and advantages of the currentembodiments will be, or will become, apparent to one of ordinary skillin the art upon examination of the following figures and detaileddescription. It is intended that all such additional systems, methods,features and advantages included within this description and thissummary, be within the scope of the invention, and be protected by thefollowing claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The current embodiments can be better understood with reference to thefollowing drawings and description. The components in the figures arenot necessarily to scale, emphasis instead being placed uponillustrating the principles of the current embodiments. Moreover, in thefigures, like reference numerals designate corresponding partsthroughout the different views.

FIG. 1 is an illustration of an exemplary modular conveyor belt;

FIG. 2 is an enlarged view of a portion of the conveyor belt shown inFIG. 1;

FIG. 3 is an illustration of an exemplary turn-curve conveyor belt;

FIG. 4 is a perspective view of an exemplary prior art flat wireconveyor belt;

FIG. 5 is a cross-sectional view of an exemplary finger style conveyorbelt;

FIG. 6 is a perspective, exploded view of two pitches of a conveyor beltembodiment including links with alignment features proximate rodreceiving apertures;

FIG. 7 is a partial plan view of an assembled conveyor belt embodimentincluding links having alignment features, where the alignment featureshave been used to properly position the rod receiving apertures to forma rod receiving pathway;

FIG. 8 is an enlarged, partial cross-sectional view of a portion of aconveyor belt embodiment including links with alignment features on thelink legs proximate rod receiving apertures;

FIG. 9 is an enlarged, partial plan view of the link legs shown in FIG.8;

FIG. 10 is an enlarged partial side view of another embodiment of twoadjacent and interconnected links with alignment features proximate therod receiving apertures, with the rod receiving apertures properlyaligned;

FIG. 11 is an enlarged partial side view of the links shown in FIG. 10,where the links are angled with respect to each other and the rodreceiving apertures remain properly aligned;

FIG. 12 is a plan view of several links of a pitch of another conveyorbelt embodiment, where each link includes alignment features and an endlink includes a retention cage;

FIG. 13 is an enlarged partial-perspective view of links of theembodiment shown in FIG. 12;

FIG. 14 is a plan view of two pitches of an assembled conveyor beltembodiment, including alignment features;

FIG. 15 is an enlarged view of a portion of FIG. 14 showing engagedalignment features of two links;

FIG. 16 is a flowchart illustrating an exemplary method for assembling aconveyor belt;

FIG. 17 is a perspective view of two adjoining links of a conveyor beltembodiment including alignment features;

FIG. 18 illustrates enlarged cross-sectional views of links of aconveyor belt embodiment during execution of an alignment procedureusing alignment features of the two links;

FIG. 19 is a perspective view of two adjoining links of a conveyor beltembodiment including alignment features;

FIG. 20 is a cross-sectional view of the links of the embodiment shownin FIG. 19;

FIG. 21 is a perspective view of two adjoining links of a conveyor beltembodiment including frangible alignment features;

FIG. 22 illustrates assembly of the links shown in FIG. 21;

FIG. 23 is a cross-sectional view of two adjoining links of a conveyorbelt embodiment including frangible alignment features;

FIG. 24 illustrates assembly of the links shown in FIG. 23 using thefrangible alignment features;

FIG. 25 illustrates the process of breaking the frangible alignmentfeatures of the embodiment shown in FIG. 23;

FIG. 26 is an alternative embodiment of a frangible alignment feature;

FIG. 27 is a perspective view of two adjoining links of a conveyor beltembodiment including frangible alignment features;

FIG. 28 is a perspective view of adjacent links of an exemplary fingerstyle conveyor belt including alignment features.

FIG. 29 is a plan view of the embodiment shown in FIG. 28;

FIG. 30 is a plan view of another exemplary finger style conveyor beltembodiment including alignment features;

FIG. 31 is a plan view of another exemplary finger style conveyor beltembodiment including alignment features; and

FIG. 32 is a plan view of another exemplary finger style conveyor beltembodiment including alignment features.

DETAILED DESCRIPTION

The present disclosure describes systems and methods for aligning themodular links of a conveyor belt for assembly.

Embodiments provide systems and methods for aligning rod receivingapertures of adjacent links to facilitate insertion of retaining rods.The presently disclosed conveyor belt concepts, such as rod alignmentfeatures, are generally applicable to a wide range of modular conveyorbelt configurations.

Examples of basic conveyor belt structures and manufacturing methods canbe found in U.S. Pat. No. 5,954,188, which is incorporated herein byreference. The accompanying FIG. 1 corresponds to FIG. 1 of the '188patent, and illustrates a typical prior art modular conveyor belt 10.Conveyor belt 10 includes rods 12 connected by links 14 and covered by amesh 16 to provide additional support for the goods transported onconveyor belt 10.

In some cases, a buttonhead 18 may be formed on the ends of rods 12 toact as a stop for links 14. A weld is also typically formed betweenbuttonhead 18 and link 14 for a stronger and more secure connectionbetween rods 12 and links 14. In other cases, a buttonless configurationmay be employed, wherein the rod is welded to the link without creatinga significant protrusion beyond the leg of the link.

FIG. 2 shows an enlarged view of a portion of prior art conveyor belt10, showing rods 12 formed with buttonheads 18. In addition, FIG. 2 alsoshows a weld 20 fastening buttonhead 18 and, therefore, rod 12, to link14.

The term “conveyor belt,” as used in the present disclosure, generallyrefers to any type of endless track or belt, typically configured to bedriven by a geared mechanism or drum. The term “conveyor belt” shouldnot be considered to be limited to any particular type of conveyor beltunless otherwise specified herein.

The directional term “lateral” or “laterally,” as used in the presentdisclosure, refers to an outwardly direction relative to the centerlineof the entire conveyor belt. A lateral link may be considered the endlink or terminal link of a row.

The term “longitudinal” as used in the present disclosure and claimsrefers to a direction in which the conveyor belt travels. Further theterm longitudinal refers to both forward and backward directions ofconveyor belt travel.

The term “vertical,” as used in the present disclosure and claims refersto the up and down direction relative to the ground.

The conveyor belt systems, and methods of building such systems, asdescribed herein, may include different types of conveyor belts. In someembodiments, the conveyor belts may be modular conveyor belts. Modularbelts may be formed of intermeshing modules, disposed in laterallyextending rows, that are rotatably joined longitudinally. In some cases,a row of a modular belt may include multiple modules disposed laterally,and joined, for example, by a connecting rod. Modular belt modules mayinclude laterally-aligned rod holes or slots at the forward and rearwardportions of each row.

The term “link,” as used in the present disclosure and claims, refers toa basic component of a conveyor belt row. For example, one individuallink may be repeated laterally in order to form an entire row of links.In some embodiments, only two links per row are provided (at each end ofthe rod). In some embodiments, the links are capable of rotatingindependently from one another. In some embodiments, two or more linksmay be rigidly attached to one another.

The term “rod” or “connecting rod” refers herein to an elongated memberused to associate links together. When associated, the links and rodform a basic modular conveyor belt.

The term “pitch” refers herein to one row of links extending from onelateral end of the conveyor belt to the opposite lateral end. In someembodiments, the pitch may be formed of one piece so that all the linksin the same row are rigidly attached to one another. In otherembodiments, the pitch may have multiple individual links arrangedside-to-side, allowing each individual link to rotate with respect toone another. In other embodiments, the pitch may include a minimalnumber of links, such as only end links connected by connecting rods. Insome embodiments, the pitch may include not only end links, but also oneor more spaced-apart intermediate links positioned between the end linksalong the connecting rod.

The term “end link” refers herein to the most laterally disposed link inthe pitch, or the terminating link for the pitch in a row. In someembodiments each pitch may have two end links, one end link for eachside of the conveyor belt.

The term “retention cage” refers herein to a structure that isassociated with the end link such that the retention cage is located onthe side of the end link that is outward from the centerline of theconveyor belt. In other words, the retention cage forms the edge of theconveyor belt. In some embodiments, the retention cage secures theconnecting rod so that the rod is not inadvertently removed from theconveyor belt during operation, assembly, or any other time.

FIG. 3 shows a top view of an exemplary modular conveyor belt 22. Asillustrated in FIG. 3, conveyor belt 22 may include a plurality of links24 connected by a plurality of elongated rods 26. A center line 28indicates the approximate midline of conveyor belt 22. Conveyor belt 22may include outer ends 30. For purposes of this disclosure, the term“outer,” as used in this description and the appended claims, shallrefer to a direction toward outer ends 30 of conveyor belt 22 and awayfrom center line 28. Conversely, the term “inner” shall refer to adirection toward center line 28 and away from outer ends 30 of conveyorbelt 22. In addition, for purposes of this disclosure, the term“longitudinal direction” shall refer to the direction in which centerline 28 is oriented.

As shown in FIG. 3, all of rods 26 may be substantially similar in shapeand dimension, with each of rods 26 being an elongated cylindrical bodyformed of an elongated portion of a rod material. In some embodiments,rods 26 may be made from a metal material, such as steel, stainlesssteel, aluminum, titanium, and/or other metals. In other embodiments,rods 26 may be made from a non-metallic material, such as plastic, wood,carbon fiber, and/or other non-metallic materials. In some embodiments,rod 26 may be a substantially hollow tube or pipe. In other embodiments,rod 26 may be solid.

The inner portions of rods 26 (near center line 28) are truncated inFIG. 3 for purposes of illustration. Rods 26 may be any suitable lengthfor supporting and carrying a variety of wares. In some embodiments,rods 26 may have a uniform or substantially uniform diameter along thelength of the cylindrical body. The diameter may be selected based uponfactors such as the type of goods being moved on conveyor belt 22, thewidth of conveyor belt 22, and/or other considerations. In someembodiments, rods 26 may include tapering or stepped configurations.

As shown in FIG. 3, rods 26 may be operatively connected to each otherwith links 24. In some embodiments, links 24 may be substantiallyU-shaped, wherein each link 24 is constructed with two legs, includingan inner leg 32 and an outer leg 34, joined by a connecting member 36.In some embodiments, inner leg 32 and outer leg 34 may be mirror-imageforms. Accordingly, as the configuration of inner leg 32 and outer leg34 are identical save for opposing orientation, for the sake of clarity,only the structure of outer leg 34 is discussed with particularity.Outer leg 34 may include a relatively straight upper portion 38connected by an outwardly-tapering transition region 40 to a relativelystraight lower portion 42. This configuration creates a wider loweropening 44 to allow for the interconnection of links 24, as connectingmember 36 of one link may readily slide into a nesting relationship withlower portion 42 of an adjacent link. In some embodiments, the fitmentof one link within another may be a relatively loose fitment, allowingseveral millimeters of lateral movement between the components. In otherembodiments, the fitment may be substantially tighter, leaving onlyminimal space between the components, and thus, maintaining the links ina consistent alignment when nested.

It will be appreciated that the form of the links joining togetherelongate rods is not limited to the configurations shown and discussedin the present disclosure. In some embodiments, the configuration of theconnective links may be simpler than link 24. For example, in someembodiments, each leg of the link may include a single straight portion.Alternatively, the configuration of the connective link may be moreinvolved for certain applications. For example, embodiments areenvisioned wherein the connective links have more bends and/or a morecomplex shape than link 24. In addition, although inner leg 32 and outerleg 34 are shown in the accompanying drawings as having mirror images ofeach other to provide symmetry for link 24, in other embodiments, link24 may be asymmetrical.

Each rod 26 may be fixedly attached to two links 24 (for example bywelding), one at each end of the rod, forming a pitch 46. Pitches 46 maybe rotatably connected to one another. For example, each rod 26 may passthrough openings 48 in upper portions 38 of outer legs 34 and throughcorresponding openings in inner legs 32. While rods 26 may be fixedlyattached to outer leg 34 at or near opening 50 in lower portion 42, rods26 may be free to rotate within the openings 48 in upper portions 38 andthe counterpart openings in inner legs 32.

In some cases, conveyor belts may be configured for a straight path ofconveyance. Such belts are often referred to as “straight run” conveyorbelts. In other cases, conveyor belts may be configured for turninglaterally to the left and/or right. Such belts are often referred to as“turn curve” conveyor belts. In order to navigate curves, modularconveyor belts may be collapsible longitudinally. In some cases, theentire width of the belt may be collapsible longitudinally. In othercases, only one end of the belt may be collapsible, for example, whenthe belt is only needed to turn in one direction. Belts may be madecollapsible by utilizing longitudinally oriented slots instead ofcircular holes to receive the rods. The structure that enablescollapsibility of conveyor belts is discussed in greater detail below.

Conveyor belt 22, as shown in FIG. 3, may be a collapsible type ofconveyor belt. That is, the belt pitches may be movable longitudinallywith respect to one another. In order to facilitate this longitudinalcollapsibility, the openings 48 in upper portions 38 of outer legs 34and counterpart openings in inner legs 32 may be longitudinally slotted,as shown in FIG. 3, thus allowing for longitudinal translation of a rodof a given pitch 46 within a link of an adjoining pitch.

Conveyor belt 22 may be collapsible at both outer ends 30 or at only oneof outer ends 30. Further, in some embodiments, outer ends 30 may beindependently collapsible, that is, each end 30 may be collapsibleindependent of the opposite outer end 30 of conveyor belt 22. Thisindependent collapsibility may enable conveyor belt 22 to be propelledaround turns. That is, when being propelled around a turn, the outer end30 of conveyor belt 22 that is on the inside of the turn may collapselongitudinally, whereas the outer end 30 on the outside of the turn mayremain expanded longitudinally. Such a conveyor belt may be referred toas a “turn-curve” conveyor belt.

Conveyor belt 22 may be driven, pulled, propelled, and/or guided by astructure such as a drum 52. Drum 52 may have a drive surface 54, whichmay contact outer end 30 of conveyor belt 22. In some embodiments, drum52 may be configured to simply guide conveyor belt 22 along a designatedpath. That is, a separate drive mechanism may propel conveyor belt 22,and drum 52 may guide conveyor belt 22 along the designated path. Inother embodiments, drum 52, in addition to guiding conveyor belt 22, mayalso be configured to propel conveyor belt 22. Thus, conveyor belt 22may be configured to contact drive surface 54.

The drive surface of the drum or other such propulsion or guidancedevice may be configured to engage a conveyor belt. The drive surfacemay be made of any suitable material for such contact. For example, thedrive surface of the drum may be made of rubber, plastic, metal, andother suitable materials. These materials can be hard, abrasive, and/ormay carry debris that acts as an abrasive during contact of the drivesurface with the contact weld on an outer portion of the conveyor belt.

In some cases, conveyor belts may be flat top belts. Flat top belts aremanufactured with a support surface on one face of the links so that thesurface abuts an adjacent link, therefore leaving no significant openareas between rows, or pitches.

In some embodiments, the belts may be picket style belts. Picket stylebelts have transverse links resembling the shape of a square wavemathematical function. The links in picket style belts have laterallyaligned rod holes or slots allowing for a connecting rod to be inserted.

In some cases, the pickets or “pitches” of picket style belts may havethe formed of an oscillating flat member. Such picket style belts arereferred to as “flat wire” style belts. Examples of basic flat wirestyle conveyor belt structures and manufacturing methods can be found inU.S. Pat. Nos. 4,846,339 and 5,954,188, which are incorporated herein byreference. These structures and methods of manufacturing are generallyapplicable to the conveyor belt embodiments described herein.

FIG. 4 is a schematic view of two pitches of a prior art flat wire styleconveyor belt 60. As can be seen in FIG. 4, flat wire belt 60 mayinclude a first pitch 62, which may have multiple rod receivingapertures 64. Belt 60 may also include a second pitch 66. Second pitch66 may also include multiple rod receiving apertures 68. When rodreceiving apertures 64 are aligned with rod receiving apertures 68, asubstantially straight rod receiving path, configured to receive aconnecting rod 70, is formed extending transversely across second pitch66.

In order to assemble a conveyor belt using first pitch 62 and secondpitch 66, first pitch 62 may be positioned adjacent to a second pitch66. First pitch 62 is then engaged with or interconnected with secondpitch 66 so that first pitch rod receiving apertures 64 align withsecond pitch rod receiving apertures 68 to form a rod receiving path.The rod receiving path enables connecting rod 70 to be pushed throughboth first pitch rod receiving apertures 64 and second pitch rodreceiving apertures 68 to associate first pitch 62 and second pitch 66.

Another type of modular conveyor belt is a finger style belt. Fingerstyle belts may include links that feature a straight or zig-zag centraltransverse rib from which finger-like protrusions extend in the forwardand/or rearward direction. The fingers typically have laterally alignedrod holes or slots allowing for a connection rod to be inserted.

FIG. 5 illustrates an exemplary finger style belt 80. As shown in FIG.5, belt 80 may include a first pitch 82 hingedly connected to a secondpitch 84 via a connecting rod 86. Each pitch of belt 80 may include azig-zag transverse rib 88. In addition, each pitch may includealternating finger-like protrusions 90, which may include rod receivingapertures 92 configured to receive connecting rod 86. In order toassemble belt 80, apertures 92 on one pitch may be aligned withapertures 92 on an adjacent pitch to form a rod receiving path, throughwhich connecting rod may be inserted to connect the pitches to oneanother.

In some cases, the pitches, especially those made of plastics, may havea certain amount of flexibility, which can complicate the alignmentprocess. Therefore, the alignment process can take a significant amountof time. In addition, in some cases, the components of the conveyor beltmay not lend themselves well to automated assembly. Accordingly,assembly, including the alignment process described above, may beperformed by a skilled belt assembler, who may be more expensive toemploy than a comparable employee without such a specialized skill.Thus, assembling traditional conveyor belts without alignment featuresmay require a significant amount of time and considerable cost.

The following discussion describes embodiments including alignmentfeatures configured to facilitate the connecting rod insertion process.The embodiments disclosed herein may be applicable to any suitable typeof conveyor belt, such as those mentioned above.

FIG. 6 shows an embodiment of two pitches of a modular, flat wire styleconveyor belt with alignment features on the legs of the links proximatethe rod receiving apertures. These alignment features are intended tosimplify the alignment process to reduce assembly time and cost.

As can be seen in FIG. 6, a first pitch 200 may have a first first pitchrod receiving aperture 208, a second first pitch rod receiving aperture202, a third first pitch rod receiving aperture 214, a fourth firstpitch rod receiving aperture 224, and a fifth first pitch rod receivingaperture 226 forming a substantially straight first line extendingtransversely across first pitch 200 to create a first insertion path fora first connecting rod 285. Additionally, first pitch 200 may have asixth first pitch rod receiving aperture 206, a seventh first pitch rodreceiving aperture 204, an eighth first pitch rod receiving aperture218, a ninth first pitch rod receiving aperture 220, and a tenth firstpitch rod receiving aperture 230, forming a substantially straightsecond line extending transversely across second first pitch 200 tocreate a second insertion path for a second connecting rod 280.

The second insertion path may also include rod receiving apertures in asecond pitch 250, including a first second pitch rod receiving aperture258, a second second pitch rod receiving aperture 252, a third secondpitch rod receiving aperture 264, a fourth second pitch rod receivingaperture 268, and a fifth second pitch rod receiving aperture 270. Firstsecond pitch rod receiving aperture 258 aligns with sixth first pitchrod receiving aperture 206, second second pitch rod receiving aperture252 aligns with seventh first pitch rod receiving aperture 204, thirdsecond pitch rod receiving aperture 264 aligns with eighth first pitchrod receiving aperture 218, fourth second pitch rod receiving aperture268 aligns with ninth first pitch rod receiving aperture 220, and fifthsecond pitch rod receiving aperture 270 aligns with tenth first pitchrod receiving aperture 230 to form the second insertion path for thesecond connecting rod 280. Arrows in FIG. 6 show the direction thatsecond pitch 250 may be moved in order to bring second pitch 250 intoproper alignment with first pitch 200 in order to form a complete secondinsertion path for the second connecting rod 280.

In order to aid in the alignment process, the pitches may be providedwith protrusions disposed proximate to the rod receiving apertures. Insome embodiments, the protrusions may surround or partially surround oneor more of the rod receiving apertures. Each protrusion may extendoutwardly a predetermined distance from the surface of the pitch, sothat the protrusion has an outer side surface spaced from the surface ofthe pitch.

In addition, the protrusions may have at least one mating surface thatmay be configured to abut a corresponding mating surface on a portion ofanother pitch. The mating surface may have any suitable shape. Forexample, in some embodiments, the protrusions may have acircular/cylindrical shape. For example, in some embodiments, theprotrusion may be a substantially cylindrical flange extending about therod receiving aperture. Such circular/cylindrical protrusions may havecurved or rounded mating surfaces. Curved or rounded mating surfaces mayenable the pitches to rotate with respect to one another. In addition,cylindrical flanges may form and function as part of the rod receivingapertures.

In other embodiments, the protrusion may have another shape (other thancircular/cylindrical), such as oval, semi-circular, linear, polygonal,or other suitable shapes, depending on factors such as the desiredrelative motion of the assembled pitches. In some embodiments, themating surface may be substantially planar. In addition, in someembodiments, the mating surface of the protrusion may be substantiallyperpendicular to the surface of the pitch from which it extends. Inother embodiments, the mating surface of the protrusion may be slopedrelative to the surface of pitch.

As can be seen in FIG. 6, conveyor belt alignment features may include afirst cylindrical protrusion 210, which may surround sixth first pitchrod receiving aperture 206. In addition, a second cylindrical protrusion216 may surround eighth first pitch rod receiving aperture 218, and athird cylindrical protrusion 228 may surround tenth first pitch rodreceiving aperture 230. A cylindrical protrusion 263 similar to firstcylindrical protrusion 210 may also surround seventh first pitch rodreceiving aperture 204. In addition, a cylindrical protrusion 267 may bedisposed proximate ninth first pitch rod receiving aperture 220.Protrusions 263 and 267 are shown in phantom since these elements aredisposed on a hidden surface of pitch 200.

As shown in FIG. 6, additional alignment features may include a firstprotrusion 262 proximate second second pitch rod receiving aperture 252,as well as a second protrusion 266 proximate fourth second pitch rodreceiving aperture 268. In some embodiments, second protrusion 266 maybe disposed proximate second pitch rod receiving aperture 268substantially in vertical alignment with second pitch rod receivingaperture 268. In other embodiments, the protrusion may be disposedproximate the rod receiving aperture in an alternative alignment. Forexample, as discussed in greater detail below, in some embodiments, theprotrusion may be disposed proximate the rod receiving aperturesubstantially in longitudinal alignment with the rod receiving aperture.

In some embodiments, the protrusion may be substantially wedge-shaped.For example, first protrusion 262 may be sloped in height, so that theportion of first protrusion 262 located furthest away from second secondpitch rod receiving aperture 252 may be substantially even, or flush,with the surface of second pitch 250, and the portion of firstprotrusion 262 closest to second second pitch rod receiving aperture 252may extend a first distance from the surface of second pitch 250. Theportion of first protrusion 262 closest to second second pitch rodreceiving aperture 252 may extend outwardly from the surface of secondpitch 250 in order to form a mating surface that may be configured toabut the mating surface of a cylindrical protrusion 263 disposedproximate aperture 204 in pitch 200.

Similarly to the protrusion discussed above, second protrusion 266 maybe sloped in height, so that the portion of second protrusion 262located furthest away from fourth second pitch rod receiving aperture268 may be substantially even, or flush, with the surface of secondpitch 250, and the portion of second protrusion 266 closest to fourthsecond pitch rod receiving aperture 268 may extend a first distance fromthe surface of the second pitch 250. The portion of second protrusion266 closest to fourth second pitch rod receiving aperture 268 may extendoutwardly from the surface of second pitch 250 in order to form a matingsurface that may be substantially perpendicular to the surface of thesecond pitch 250. A wedge-shaped protrusion 259 similar to 262 may alsobe disposed proximate first second pitch rod receiving aperture 258. Asshown in FIG. 6, protrusion 259 may be configured to abut protrusion 210on first pitch 200. Additional wedge-shaped protrusions 265 and 271 maybe disposed proximate apertures 264 and 270 respectively.

Alignment features, such as wedge-shaped protrusions may be formed byany suitable method. In some embodiments, the features may be molded(plastic) or stamped (metal) into the form of a pitch. In someembodiments, the features may be formed by deforming/displacing materialon the surface of the pitch.

FIG. 7 is a plan view of an embodiment of a conveyor belt with alignmentfeatures associated with the legs of the links. In FIG. 7, a third pitch300 may have third pitch rod receiving apertures 320 that extendtransversely through third pitch 300. Similarly, a fourth pitch 350 mayhave fourth pitch rod receiving apertures 370 that extend transverselythrough fourth pitch 350. Third pitch rod receiving apertures 320 areconfigured to be aligned with fourth pitch rod receiving apertures 370to assemble the pitches into a portion of a conveyor belt by inserting aconnecting rod through the aligned rod receiving apertures, which form arod receiving path through the pitches.

Alignment features on third pitch 300 may include cylindricalprotrusions 310 that may extend outwardly some distance from the surfaceof the third pitch 300, so that the cylindrical protrusions 310 may havean outer side surface that may be substantially perpendicular to thesurface of the pitch 300. The cylindrical protrusions 310 shown in FIG.7 surround third pitch rod receiving apertures 320 that extendtransversely through the third pitch 300.

Alignment features on the fourth pitch 350 may include wedge-shapedprotrusions 360 near rod receiving apertures 370. The wedge-shapedprotrusions 360 may be sloped in height, so that the portion of theprotrusions 360 furthest from the rod receiving apertures 370 may besubstantially even with the surface of the fourth pitch 350 and theportion of the protrusions 360 closest to the rod receiving apertures370 may extend a first distance from the surface of the fourth pitch350. The portion of the protrusions 360 closest to fourth pitch rodreceiving apertures 370 may extend outwardly from the surface of fourthpitch 350 in order to form a side surface that may be substantiallyperpendicular to the surface of fourth pitch 350.

In order to align third pitch rod receiving apertures 320 with fourthpitch rod receiving apertures 370, mating surfaces of wedge-shapedprotrusions 360 located on fourth pitch 350 may be engaged with matingsurfaces of cylindrical protrusion 310 located on third pitch 300. Theengagement of wedge-shaped protrusions 360 and cylindrical protrusions310 may be achieved by abutting wedge-shaped protrusions 360 against theside walls of cylindrical protrusions 310. The wedge-shaped protrusions360 and the cylindrical protrusions 310 may be formed so that when themating surfaces are brought into contact with, or close proximity to,one another, third pitch rod receiving apertures 320 are properlyaligned with fourth pitch rod receiving apertures 370 so that aconnecting rod may be easily pushed through all of the third pitch rodreceiving apertures 320 and fourth pitch rod receiving apertures 370without being impeded and/or encountering obstructions in the rodreceiving path.

Once the rod receiving apertures 320 in the third pitch 300 are properlyaligned with the rod receiving apertures 370 in the fourth pitch 350,the connecting rod 390 may be inserted into rod receiving apertures 320and 350 in order to fixedly attach the third pitch 300 to the fourthpitch 350. Although the third pitch 300 may be fixedly attached to thefourth pitch 350 in FIG. 7, the third pitch 300 and the fourth pitch 350may still rotate independent of one another about the longitudinal axisof the connecting rod 390.

FIG. 8 is an enlarged plan view of a portion of an embodiment of twolinks of a conveyor belt with alignment features. In FIG. 8, a firstlink 410 from a first pitch 411 may be attached to a second link 420from a second adjacent pitch 421. The first link 410 may have a rodreceiving aperture 405 on one end 415. The second link 420 from secondpitch 421 may have a rod receiving aperture 422 on one end 425. Awedge-shaped protrusion 430 may be disposed on a surface 446 of firstlink 410. In addition, second link 420 may include a cylindricalprotrusion 445 disposed proximate rod receiving aperture 422.

FIG. 9 is an enlarged side view of the link legs shown in FIG. 8relating to an embodiment of links of a conveyor belt with alignmentfeatures. As shown in FIG. 9, a proximal edge forming a mating surface434 of wedge-shaped protrusion 430 may be located a distance R from thecenter of the rod receiving aperture 405. Wedge-shaped protrusion 430may be sloped in height so that distal edge 432, furthest away from therod receiving aperture 405, may be substantially the same height assurface 446 of first link 410. Mating surface 434, which is closest torod receiving aperture 405, may extend a first distance from surface 446of first link 410. In some embodiments, the mating surface formed bymating surface 434 may be substantially perpendicular to surface 446 offirst link 410. In some embodiments, mating surface 434 may extendapproximately 0.5 mm from the surface of the first link 410. In otherembodiments, the mating surface 434 may extend more or less than 0.5 mmfrom the surface of the first link 410. As shown in FIG. 9, matingsurface 434 may be disposed facing in the direction of rod receivingaperture 405.

In some embodiments, mating surface 434 may be substantially planar, asshown in FIGS. 6-15. In other embodiments, as will be discussed ingreater detail below, the mating surface may be curved. For example, themating surface may be curved to mate with the mating surface of a matingprotrusion (e.g., protrusion 440).

As shown in FIG. 9, cylindrical protrusion 445 may extend outwardly apredetermined distance from a surface 460 of second link 420, so thatcylindrical protrusion 445 has mating surface 442 and an inner sidesurface 441, both of which may be substantially perpendicular to surface460 of second link 420. In some embodiments, outer side surface 442 ofcylindrical protrusion 445 may extend 0.5 mm from the surface of firstlink 410. In other words, the height of mating surface 442 may beapproximately equal to 0.5 mm. In other embodiments, mating surface 442of cylindrical protrusion 445 may extend more or less than 0.5 mm fromsurface 460 of second link 420. Mating surface 442 of cylindricalprotrusion 420 may have a radius R so that mating surface 442 ofcylindrical protrusion 445 may abut the mating surface formed byproximal edge 434 of wedge-shaped protrusion 430 on first link 410.

Although protrusion 430 on first link 410 is shown as wedge-shaped inFIG. 8, protrusion 430 may have any suitable form including a matingsurface facing rod receiving aperture 405. For example, in someembodiments, protrusion 430 may form a bump, or other type ofprojection, extending from surface 446 of first link 410. In someembodiments, the bump or projection may extend approximately 0.5 mm fromsurface 446 of first link 410. In other embodiments, the bump orprojection may extend more or less than 0.5 mm from surface 446 of firstlink 410. In some embodiments, the bump or projection may be formed bysoldering or welding material onto surface 446 of first link 410. Insome embodiments, the bump or projection may extend outwardly fromsurface 446 of first link 410 in order to form a mating surfaceconfigured to abut mating surface 442 of cylindrical protrusion 445 onsecond link 420.

As shown in FIG. 9, wedge-shaped protrusion 430 may include a protrudingedge 433 located a distance R from the center of rod receiving aperture405. Protruding edge 433 may be approximately 0.5 mm from surface 446 offirst link 410. As also shown in FIG. 9, in some embodiments, the heightof the wedge-shaped protrusion 430 may be substantially equal to height443 of the cylindrical protrusion 445.

Various types of materials may be used to manufacture the disclosedconveyor belt links. In some embodiments, the pitches and/or links maybe manufactured from plastic materials. For example, the pitches and/orlinks could be made from polypropylene, polyethylene, polyoxymethylene,or polyvinylidene fluoride. In some embodiments, the pitches and/orlinks may be formed by injection molding. In some embodiments, thepitches and/or links may be manufactured from metal, such as steel orstainless steel. In some embodiments, the pitches and/or links may bemade from more than one layer of material. In some embodiments, thepitches and/or links may be coated with a different material than thematerial making up the remaining components of the conveyor belt. Also,in some embodiments, the connecting rods may be made of the samematerial as the pitches and/or links. In other embodiments, theconnecting rods may be made of a different material than the pitchesand/or links. For example, in some embodiments, the pitches, includingthe links, may be formed of plastic, and the rods may be formed ofmetal.

The concepts of the present disclosure, including the discussedalignment features, may be applicable to conveyor belts assembled withconnecting rods formed of any material. As discussed above, theflexibility of the rods may influence how difficult it is to insert therods, and the flexibility of the rods may be determined by the diameterof the rods, the length of the rods, and the material used to form therods. In some cases, plastic rods may be used, whereas, in other cases,metal rods may be used. Typically, plastic rods have a larger diameterthan metal rods used for similar conveyor belts, in order to provide therods with suitable stiffness and strength. The smaller diameter of metalrods and the corresponding rod receiving apertures may make alignment ofthe apertures and insertion of the rods more difficult. Accordingly, thepresently disclosed alignment features may be more beneficial toembodiments implementing metal connecting rods. Further, the disclosedalignment features may be more beneficial to smaller diameter connectingrods in general.

FIG. 10 is a view of another embodiment of a conveyor belt withalignment features on the links with the conveyor belt links properlyaligned. FIG. 10 shows first link 410 and second link 420 from FIGS. 7and 8. As shown in FIG. 10, mating surface 434 of wedge-shapedprotrusion 430 on first link 410 may abut mating surface 442 ofcylindrical protrusion 445 on second link 420. Abutting the matingsurfaces in such a manner may result in the rod receiving aperture infirst link 410 aligning with the rod receiving aperture of second link420. A connecting rod 499 may be inserted in the rod receiving aperturesin order to fixedly attach first link 410 to second link 420.

FIG. 11 is a schematic view of the conveyor belt embodiment shown inFIGS. 8-10 with the rod receiving apertures properly aligned while thepitches/links are disposed at an angle with respect to one another byvirtue of being rotationally displaced about rod 499. The mating surface434 of wedge-shaped protrusion 430 on first link 410 may be abutted withmating surface 442 of cylindrical protrusion 445 on second link 420 atany angle α. As shown in FIG. 11, an axis 472 of first link 410 may bedisposed in substantial non-alignment with an axis 470 of second link420. Even while disposed in substantial non-alignment, mating surface434 of wedge shaped protrusion 430 may still be mated with matingsurface 442 of cylindrical protrusion 445 in order to align rodreceiving aperture in first link 410 with the rod receiving aperture insecond link 420. In other words, in some embodiments, the protrusionsmay be configured to not act as stops for the relative rotation of thelinks of an assembled conveyor belt. In such embodiments, theprotrusions may simply act as stops for the advancement of links towardseach other during manufacturing, while allowing rotational movement ofthe links relative to one another.

FIG. 12 is a schematic view of a pitch 700 of a different picket styleconveyor belt. Pitch 700, unlike pitch 250 shown in FIG. 4, is notflattened in all locations, and instead includes substantiallycylindrical connecting portions through which the connecting rods may beinserted. However, like pitch 250, pitch 700 includes similar alignmentfeatures. The alignment features may include a combination ofcylindrical protrusions 710 and wedge-shaped protrusions 720.

As shown in FIG. 12, pitch 700 may be formed of several links that arerepeated laterally. In some embodiments, the end link may or may nothave the same shape or design as the remaining links in the same row. Insome embodiments, the end link may be associated with a retention cageadapted to retain a connecting rod without welding, forming buttonheads, adhering, or otherwise fastening the rod into position.Embodiments of such rod retaining features are more fully disclosed inU.S. Patent Publication No. 2013/0140146; U.S. Patent Publication No.2013/0140149; U.S. Pat. No. 8,636,141; U.S. Pat. No. 8,607,967; and U.S.Patent Publication No. 2013/0140152, each of which is filed on even dateherewith, is entitled “Conveyor Belt Link with Rod Retaining Feature,”and is incorporated herein in its entirety by reference.

FIG. 13 is a more detailed view of the pitch in FIG. 12. As can be seenin FIG. 13, pitch 700 may include a combination of cylindricalprotrusions 710 and wedge-shaped protrusions 720.

FIG. 14 is a schematic view of a portion of a conveyor belt embodimentformed from the joinder of pitches like that shown in FIG. 13. As shownin FIG. 14, the mating surface of cylindrical protrusions 810 on pitch800 may be mated with the mating surface of wedge-shaped protrusions 720on a pitch 700. A connecting rod 825 has been inserted through rodreceiving apertures throughout pitch 700 and pitch 800. The first pitch700 also has cylindrical protrusions 710 which may be mated withwedge-shaped protrusions of an adjacent pitch (not shown) in theconveyor belt. Similarly, the second pitch 800 has wedge-shapedprotrusions 820 which may be mated with cylindrical protrusions of anadjacent pitch (not shown) in the conveyor belt. Although pitch 700 andpitch 800 are attached by a connecting rod, pitch 700 may rotate aboutrod 825 independently of pitch 800.

FIG. 15 is an enlarged view of a portion of FIG. 14. As can be seen inFIG. 15, a mating surface 725 of wedge-shaped member 720 located onfirst pitch 700 may abut a mating surface 815 of cylindrical protrusion810 located on second pitch 800. As illustrated in FIG. 15, the lateralfacing surface of cylindrical protrusion 810 may serve as a bearingsurface as it contacts the lateral facing surface of the link of pitch700.

FIG. 16 is a flowchart illustrating steps of an exemplary method forassembling a conveyor belt. The method may include a step 1210 ofproviding a first link with a circular protrusion. Although step 1210may involve a link with a circular protrusion, the protrusion may be anyother shape forming a mating surface extending a distance from thesurface of the link. The method may also include a step 1220 ofproviding a second link having a wedge-shaped protrusion. Although step1220 involves a link with a wedge-shaped protrusion, the protrusion maybe any other shape forming a mating surface extending a first distancefrom the surface of the link. The method may also include a step 1230 ofaligning the two links by moving the links together until a side surfaceof the circular protrusion abuts the side surface of the wedge-shapedprotrusion.

FIG. 17 illustrates another embodiment of a conveyor belt havingalignment features. The conveyor belt is shown in FIG. 17 is a flat wirestyle conveyor belt for simplicity of discussion and illustrations.However, the alignment features included in the embodiment shown in FIG.17 may be applicable to any other suitable modular conveyor belt.

FIG. 17 illustrates alignment features similar to those shown in FIGS.6-15. For example, the alignment features may include protrusionsdisposed on interlinking pitches, wherein the protrusions have matingsurfaces configured such that when the pitches are arranged with themating surfaces abutting, rod receiving apertures in the two pitches arealigned to form a rod receiving path. Once the rod receiving path isformed by aligning the apertures, a connecting rod may be insertedthrough the apertures. The protrusions may be formed as substantiallycylindrical protrusions like the embodiment shown in FIGS. 6-15, and themating protrusions may include block-shaped protrusions rather thanwedge-shaped protrusions. In addition, the block-shaped protrusions maybe disposed in longitudinal alignment with the apertures instead ofvertical alignment.

As shown in FIG. 17, a modular conveyor belt 1400 may include a firstpitch 1405 and a second pitch 1410. First pitch 1405 may include a firstlink 1415 and second pitch 1410 may include a second link 1420. In someembodiments, the links may be substantially U-shaped. For example, firstlink 1415 may include a first leg 1421, a second leg 1422, and aconnecting portion 1423.

Belt 1400 may be assembled by translating first pitch 1405 and secondpitch 1410 relative to one another in a longitudinal direction. Forexample, in some embodiments, second pitch 1410 may be moved along alongitudinal axis 1425 in a direction indicated by an arrow 1430 toalign a first rod receiving aperture 1435 with a second rod receivingaperture 1440. The alignment of apertures 1435 and 1440 may befacilitated by a block-shaped protrusion 1445 disposed proximate toaperture 1435 and a substantially cylindrical protrusion 1450 disposedabout aperture 1440.

Aperture 1435 and block-shaped protrusion 1445 may be disposed on firstleg 1421 of first link 1415. In some embodiments, correspondingalignment features may also be provided on second leg 1422 of first link1415. For example, a second block-shaped protrusion 1455 may be disposedproximate to a rod receiving aperture 1460 on first link 1415, and amating second substantially cylindrical protrusion 1465 may be disposedproximate to a rod receiving aperture 1470 on second link 1420.

It should be noted that, although belt 1400 is illustrated with matingalignment features on each leg of the links, in some embodiments, thealignment features may be provided on only one leg of each link.Further, in some embodiments, every link of each pitch may includealignment features, as shown in the embodiments illustrated in theaccompanying figures. However, it will be appreciated that alternativeembodiments may include fewer sets of alignment features. For example,in some embodiments alignment features may be provided only on theoutermost links or the outermost legs of the outermost links of a pitch.In some embodiments, alignment features may be provided on alternatinglinks. In still other embodiments, alignment features may be provided atthe outer edges and in a central portion of the pitches only. In otherembodiments, alignment features may be provided at any suitable spacedintervals along the pitches. Also, the alignment features may be thesame or different at forward and rearward portions of a given pitch.

Further, in some embodiments, alignment features or other structuralfeatures of the pitches may be asymmetrical in various orientations tofacilitate correct orientation of components during assembly. Inaddition, in some embodiments, all pitches of a modular conveyor beltmay be identical (and thus include identical alignment features). Inother embodiments, a belt may be formed of dissimilar pitches, forexample, two alternating pitch structures. In some embodiments, thepitch structures may be the same except for differing alignmentfeatures, which may prevent assembly of identical pitches havingidentical alignment features in adjacent positions on a belt. In someembodiments, different components of a cooperating pair of alignmentfeatures may be arranged on the same side of a single link or picket.Further, in some embodiments, identical features may be arranged on alllinks or pickets on both leading and trailing sides of a pitch, suchthat the pitch may function identically when reversed about lateral,longitudinal, or vertical axes.

It should also be noted that the alignment features may be disposed onany side of the rod receiving apertures, with the understanding thatplacement of the alignment features may impact the ability to rotate thelinks relative to one another once the belt is assembled, which couldaffect the ability of the belt to flex during conveyance. In addition,alignment features may be formed to allow for a certain amount of playin the components in order to accommodate slight misalignment ofcomponents due to manufacturing tolerances.

In some embodiments, an alignment protrusion may be disposedsubstantially in longitudinal alignment with a rod receiving aperture.For example, as shown in FIG. 17, block-shaped protrusion 1445 may bedisposed substantially in longitudinal alignment with aperture 1435.That is, block-shaped protrusion 1445 may be disposed in the samelongitudinal position along the longitudinal length of the conveyor beltas aperture 1435.

In some embodiments one or both of the protrusions may have a curvedmating surface to enable full rotation of the pitches relative to oneanother after assembly. For example, in the embodiment shown in FIG. 17,the mating protrusion 1450 has a curved mating surface 1475. Thus, assecond pitch 1410 is rotated about a connecting rod inserted through theassembled first and second pitches 1405 and 1410, the distance betweenthe aperture and the portion of the mating surface 1475 closest to amating surface 1480 of protrusion 1445 is consistent.

Another feature of block-shaped protrusion 1445 is that mating surface1480 may be curved in a manner corresponding with mating surface 1475 ofprotrusion 1450. Not only may this curvature of the mating surfacesfacilitate rotation of the pitches relative to one another, it may alsoenable alignment in both the longitudinal and vertical directions.During assembly, the vertical alignment of apertures 1435 and 1440 isprovided by the abutting of mating surfaces 1475 and 1480. In addition,the curvature of mating surface 1480 may cradle the substantiallycylindrical protrusion 1450, providing an indication of the longitudinalalignment of aperture 1440 with aperture 1435, that is, the longitudinalpositioning of first link 1415 relative to second link 1420.

In some embodiments, alignment features may be provided on one pitchthat may be configured to abut one or more portions of a second pitch,where the second pitch does not include alignment features configured tomate with the alignment features on the first pitch. For example, insome embodiments, the links may be substantially U-shaped, including afirst leg, second leg, and a connecting portion between the legs (thebottom of the U). A first link may include a protrusion that includes amating surface that is located a predetermined distance from the rodreceiving aperture in the first link. Accordingly, the first matingsurface of the protrusion may be configured to abut a portion of asecond link including a second rod receiving aperture such that, whenthe first protrusion abuts the portion of the second link, the first rodreceiving aperture is substantially aligned with the second rodreceiving aperture to form a rod receiving path.

FIG. 18 illustrates a modular conveyor belt 1500, which may include afirst pitch 1505 and a second pitch 1510. First pitch 1505 may include afirst link 1515 and second pitch 1510 may include a second link 1520.First pitch 1505 may include a first rod receiving aperture 1535 whichmay be aligned with a second rod receiving aperture 1540 in order toprovide a rod receiving path configured to receive a connecting rod1542.

The alignment of apertures 1535 and 1540 may be facilitated by aprotrusion 1545 disposed proximate to aperture 1535. Protrusion 1545 mayhave any suitable shape and configuration. For example, as shown in FIG.18, protrusion 1545 may be substantially wedge-shaped. Wedge-shapedprotrusion 1545 may be configured to abut a portion of second link 1520.

In some embodiments, the links may be substantially U-shaped. Forexample, first link 1515 may include a first leg 1521, a second leg1522, and a connecting portion 1523. Likewise, second link may include afirst leg 1546, a second leg 1547, and a connecting portion 1548 betweenfirst leg 1546 and second leg 1547. In some embodiments, wedge-shapedprotrusion 1545 may be configured to abut connecting portion 1548 ofsecond link 1520. As illustrated in FIG. 18, wedge-shaped protrusion1545 may include a first mating surface 1575, which may be configured toabut a second mating surface 1580 of connecting portion 1548 of secondlink 1520.

In order to avoid binding of the mating surfaces after assembly, whichcan prevent relative rotation of the pitches, the alignment features maybe configured such that links to be joined are positioned with matingsurfaces abutted in order to substantially align holes, and thenrepositioned either by insertion of the connecting rod, which preciselyaligns holes, thereby drawing the mating surfaces away from each otherslightly, or by rotating the pitches relative to one another. Forexample, the protrusion may be disposed a predetermined distance fromthe rod receiving aperture such that, when the mating surfaces abut, therod receiving apertures are substantially, but not precisely, aligned,and such that when the rod is inserted and the apertures becomeprecisely aligned, the mating surfaces do not abut. In order tofacilitate insertion of the rod when the apertures are substantially,but imprecisely, aligned, the leading end of the rod and/or the edges ofone or both apertures may be beveled or chamfered.

FIG. 18 illustrates an embodiment in which the alignment feature matingsurfaces may be abutted to substantially align the apertures in links tobe joined, and then drawn out of abutment by the precise alignment ofthe apertures caused by insertion of the connecting rod. For example,when second mating surface 1580 of wedge-shaped protrusion 1545 abutsfirst mating surface 1575 of connecting portion 1548 of second link1520, second link 1520 may be nested between first leg 1521 and secondleg 1522 of first link 1515 and first rod receiving aperture 1535 may bein substantial alignment with second rod receiving aperture 1540. Insome embodiments, When second mating surface 1580 of wedge-shapedprotrusion 1545 abuts first mating surface 1575 of connecting portion1548 of second link 1520, second link 1520 may be nested between firstleg 1521 and second leg 1522 of first link 1515 further in alongitudinal direction than when first rod receiving aperture 1535 andsecond rod receiving aperture 1540 are precisely aligned.

The substantial (but imprecise) alignment is illustrated in FIG. 18 bydimensions 1582 and 1584. In order to facilitate insertion of connectingrod 1542 while apertures 1535 and 1540 are substantially (butimprecisely) aligned, in some embodiments, rod 1542 may include abeveled tip 1586. Alternatively, or additionally, aperture 1540 and/oraperture 1535 may be beveled (chamfered), as shown in FIG. 18. In someembodiments, the alignment features may be configured to positionapertures 1535 and 1540 into alignment within up to one half thediameter of rod 1542. Accordingly, in some embodiments, thebevels/chamfers on rod 1542 and/or apertures 1535 and 1540 may be up tohalf the diameter of the rod. In some embodiments, bevels/chamfers maybe provided to accommodate for misalignments due to variations inmanufacturing regardless of whether any purposeful misalignment isprovided by the alignment features.

Once rod 1542 is fully inserted, aperture 1535 and aperture 1540 maybecome precisely aligned by longitudinally translating second link 1520relative to first link 1515 slightly. Accordingly, a space equivalent todimension 1582 (and dimension 1584) will be provided between matingsurface 1575 and 1580, thereby allowing rotation of first pitch 1505relative to second pitch 1510.

In some embodiments, alignment features may be engaged with one another,such that mating surfaces are abutting, in order to align rod receivingapertures. This step may be performed with the links oriented orthogonal(perpendicular) to one another. Once the rod is inserted, the pitchesmay be rotated about the connecting rod, thereby disengaging thealignment features and enabling free rotation of the pitches relative toone another in a predetermined range of motion.

In some embodiments at least one of the alignment features may include arecess. For example, a first link may include a recess in a surface ofthe first link, wherein the recess includes a first mating surface. Therecess may be disposed proximate a first rod receiving apertureextending through the first link. In addition, at least one of thealignment features may include a protrusion that engages the recess. Forexample, a second link may include a protrusion extending a seconddistance from a surface of the second link, wherein the protrusionincludes a second mating surface. The protrusion may be disposedproximate a second rod receiving aperture extending through the secondlink, wherein, when the protrusion is engaged with the recess, the firstmating surface of the recess abuts the second mating surface of theprotrusion.

When the protrusion is engaged with the recess, the first link may be insubstantial non-alignment with the second link. For example, in someembodiments, when the protrusion is engaged with the recess, the firstlink may be oriented substantially orthogonal to the second link. Afterinsertion of a connecting rod through the apertures of the first linkand the second link, the links may be rotated such that the first linkis oriented in substantial alignment with the second link. In thisarrangement (i.e., when the first link is oriented in substantialalignment with the second link), the protrusion on the second link maybe longitudinally spaced from the first link allowing rotation of thesecond link relative to the first link about the connecting rod over apredetermined range of motion.

FIG. 19 illustrates an exemplary conveyor belt embodiment with alignmentfeatures including a recess and a mating protrusion. For example, FIG.19 shows a modular conveyor belt 1600, including a first pitch 1605 anda second pitch 1610. First pitch 1605 may include a first link 1615 andsecond pitch 1610 may include a second link 1620 configured to belongitudinally aligned along a longitudinal axis 1625. First link 1615may include a first rod receiving aperture 1635 and second link 1620 mayinclude a second rod receiving aperture 1640.

First link 1615 may include a recess 1645. Second link 1620 may includea protrusion 1650 configured to engage with recess 1645. Recess 1645 andprotrusion 1650 may have any suitable mating shapes. For example, asshown in FIG. 19, recess 1645 and protrusion 1650 may be substantiallyhemispherical. Other possible mating shapes will be recognized by thosehaving ordinary skill in the art. In addition, it will also berecognized that the degree to which protrusion 1650 and recess 1645 areengaged may vary. In some embodiments, substantially the entireprotrusion 1650 may be disposed within recess 1645 when the twocomponents are engaged. In other embodiments, only a portion ofprotrusion 1650 may be disposed within recess 1645 when the twocomponents are engaged.

In some embodiments, as shown in FIG. 19, recess 1645 may be disposedproximate to aperture 1635 in longitudinal alignment with aperture 1635.As shown in the illustrated embodiment, protrusion 1650 may be disposedproximate to aperture 1640 in vertical alignment with aperture 1640.With this configuration, protrusion 1650 may be engaged with recess 1645in order to align apertures 1635 and 1640 to create a rod receiving paththrough apertures 1635 and 1640. Accordingly, the alignment may beachieved when first pitch 1605 (and therefore first link 1615) isoriented at a substantially orthogonal (perpendicular) angle withrespect to second pitch 1610 (and therefore second link 1620). In otherembodiments, however, the recess and/or protrusion may be located suchthat mating engagement (and therefore alignment of the apertures) isachieved with the first pitch and the second pitch oriented at adifferent non-zero angle relative to one another.

The step of aligning aperture 1635 with aperture 1640 by engagement ofprotrusion 1650 with recess 1645 while first pitch 1605 is orientedorthogonal to second pitch 1610 is illustrated by an arrow labeled “1”in FIG. 19. After apertures 1635 and 1640 are aligned, a connecting rod1655 may be inserted through apertures 1635 and 1640, as illustrated bya second arrow, labeled “2” in FIG. 19. Once connecting rod 1655 isinserted, second pitch 1610 may be rotated about connecting rod 1655relative to first pitch 1605, as indicated by a third arrow, labeled “3”in FIG. 19. By rotating second pitch 1610, protrusion 1650 may bedisengaged from recess 1645.

As illustrated in FIG. 20, upon completion of this third step, firstpitch 1605 and second pitch 1610 may be in substantial alignment. Asshown in FIG. 20, in this post-assembly configuration, protrusion 1650may be located longitudinally spaced from first pitch 1605 in order toallow free rotation of the pitches relative to one another in apredetermined range of rotational motion. In addition, in someembodiments, second rod receiving aperture 1640 may be a longitudinallyelongate slot, which may enable collapsibility of belt 1600. In suchembodiments, the longitudinal spacing between protrusion 1650 and firstpitch 1605 when first pitch 1605 and second pitch 1610 are in alignmentmay be large enough to allow collapsing of first pitch 1605 and secondpitch 1610.

Further, in an alternative embodiment, recess 1645 may be disposed invertical alignment with aperture 1635. In such an embodiment, engagementof protrusion 1650 with recess 1645 may occur when first pitch 1605 andsecond pitch 1610 are oriented in substantial alignment with each other.In order to facilitate rotation of first pitch 1605 relative to secondpitch 1610 about connecting rod 1655 after assembly, in someembodiments, the engagement of protrusion 1650 with recess 1645 may beminimal, such that the elements disengage readily during relativerotation of pitches 1605 and 1610.

In some embodiments, protrusion 1650 may be frangible. For example, oncealignment of the apertures is accomplished by engaging protrusion 1650with recess 1645, relative rotation of pitches 1605 and 1610 causesprotrusion 1650 to break off, enabling free rotation of first pitch 1605relative to second pitch 1610. Protrusion 1650 may be rendered frangibleby any suitable means. For example, the junction between protrusion 1650and second link 1620 may be weakened in some way, such as withperforations and/or being formed by a thinner piece of material that isreadily breakable without damaging the portion of the link to whichprotrusion 1650 is attached. Alternatively, in some embodiments,protrusion 1650 may be formed of a soluble material. After assembly ofthe belt, the belt may be dipped in, or sprayed with, a solvent whichdissolves protrusion 1650 but does not affect the rest of the conveyorbelt components.

In some embodiments, frangible type alignment features may be configuredsuch that the belt may be used without breaking off the frangiblecomponents. In such cases, the user may have the option as to whetherthey want to break off the frangible alignment feature or use the beltwith the frangible alignment feature intact. In some embodiments,leaving the frangible alignment features intact may result in a beltthat has limited flexibility and/or collapsibility, which may besatisfactory or preferred for certain applications. Leaving thefrangible alignment features intact if breakage is not necessary mayfacilitate replacement of components and service generally. Reassemblyof a belt that has been disassembled for service may be easier andfaster if the frangible alignment features are left intact. For otherapplications, however, it may be preferred to break off the frangiblealignment features in order to allow an increased range of motion of thebelt components relative to one another. For example, removal offrangible alignment features may enable relative rotation, or a greaterrange of relative rotation, of pitches with respect to one another, aswell as longitudinal collapsibility of pitches relative to one another.Collapsibility may enable belts to navigate turns and other aspects oftortuous conveyor paths.

Other types of frangible alignment features are also envisaged. Anexemplary modular conveyor belt may include a first link having a firstrod receiving aperture and a frangible tab extending from a surface ofthe first link. The frangible tab may include a first mating surfacelocated a predetermined distance from the first rod receiving aperture.The first mating surface of the frangible tab may be configured to abuta portion of a second link including a second rod receiving aperture.When the first protrusion abuts the portion of the second link, thefirst rod receiving aperture may be substantially aligned with thesecond rod receiving aperture to form a rod receiving path.

In some embodiments a frangible tab may be disposed on an inner surfaceof a first substantially U-shaped link. The tab may serve to limitnesting of a second link within the first link in order to align the rodreceiving apertures. In such an embodiment, the aperture on the secondlink may be a longitudinally elongate slot. Once the connecting rod isinserted through the apertures, the links may be squeezed to force thesecond link further into nesting engagement with the first link and, indoing so, break off the frangible tab. Breaking off of the tab mayenable free rotation of the links relative to one another as well aslongitudinal collapsibility.

Each of the links may be substantially U-shaped, including a first leg,a second leg, and a connecting portion. The frangible tab of the firstlink may be configured to abut the connecting portion of the second linkwhen the second link is nested between the first leg and the second legof the U-shaped first link in an abutting position. In some embodiments,the second rod receiving aperture may be a longitudinally elongate slot,and the frangible tab may be configured to be broken off bylongitudinally translating the second link from the abutting position toa second position in which the second link is nested further within thefirst link.

FIG. 21 illustrates an exemplary conveyor belt embodiment with frangiblealignment features. FIG. 21 shows a modular conveyor belt 1800,including a first pitch 1805 and a second pitch 1810. First pitch 1805may include a first link 1815 and second pitch 1810 may include a secondlink 1820 configured to be longitudinally aligned along a longitudinalaxis 1825. First link 1815 and second link 1820 may be brought intoengagement, for example, by translating second link 1820 in alongitudinal direction indicated by arrow 1827. In some embodiments,either or both first link 1815 and second link 1820 may belongitudinally translated to bring the two links into engagement. Firstlink 1815 may include a first rod receiving aperture 1835 and secondlink 1820 may include a second rod receiving aperture 1840. In addition,first link 1815 may include a frangible tab 1845.

As shown in FIG. 21, in some embodiments, first link 1815 and secondlink 1820 may be substantially U-shaped. For example, first link 1815may include a first leg 1850, a second leg 1855, and a connectingportion 1860 between first leg 1850 and second leg 1855. Similarly,second link 1820 may include a first leg 1865, a second leg 1870, and aconnecting portion 1875 between first leg 1865 and second leg 1870.

Frangible tab 1845 may include a first mating surface 1880, which may beconfigured to abut a second mating surface 1885 of connecting portion1875 of second link 1820. Similar to the embodiment shown in FIG. 18,frangible tab 1845 may be disposed a predetermined distance from firstaperture 1835 such that when second link 1820 is brought into contactwith mating surface 1880 of frangible tab 1845 by translating in thelongitudinal direction (indicated by arrow 1827), apertures 1835 and1840 may be substantially aligned, creating a rod receiving path.

As shown in FIG. 22, once apertures 1835 and 1840 are substantiallyaligned, a connecting rod 1890 may be inserted in a direction indicatedby an arrow 1895 through apertures 1835 and 1840. In addition, afterconnecting rod 1890 has been inserted, because second aperture 1840 maybe a longitudinally elongate slot, second link 1820 may be translatedfurther longitudinally toward first link 1815 to break frangible tab1845, thereby enabling free rotation of first pitch 1805 relative tosecond pitch 1810 about connecting rod 1890. In addition, removal offrangible tab 1845 may also render conveyor belt 1800 collapsible.

FIGS. 23-25 are cross-sectional views illustrating the process ofassembling links 1815 and 1820. As shown in FIG. 23, second link 1820may be translated in a longitudinal direction, indicated by arrow 1827to nest within first link 1815. FIG. 24 illustrates second link 1820positioned with second mating surface 1885 of connecting portion 1875abutting first mating surface 1880 of frangible tab 1845. As shown inFIG. 24, when first mating surface 1880 abuts second mating surface1885, apertures 1835 and 1840 may be substantially aligned, creating arod receiving path, enabling connecting rod 1890 to be inserted in thedirection indicated by arrow 1895.

As shown in FIG. 25, once connecting rod 1890 has been inserted, secondlink 1820 may be translating at least a predetermined distance(indicated by a dimension 1897 in FIG. 25) in a direction indicated byan arrow 1899 in order to break frangible tab 1845 off of first link1815. This is enabled by the fact that second rod receiving aperture isa longitudinally elongate slot, thus allowing second link 1820 to betranslated longitudinally over a range of motion while connecting rod1890 remains stationary. Once frangible tab 1845 has been broken off,first and second links 1815 and 1820 may be free to be articulatedlongitudinally and rotationally relative to one another over a moreextensive range of motion in order to enable conveyance along a tortuousconveyor belt path.

Frangible tab 1845 may be rendered frangible by any suitable means. Insome embodiments, the junction between frangible tab 1845 and first link1815 may be weakened in some way. For example, in some embodiments, thisjunction may be perforated. In other embodiments, this junction maysimply be a thinner region of material. In still other embodiments, thisjunction may be both thinner and perforated. Alternatively, in someembodiments at least a portion of frangible tab 1845 may be soluble in asolution in which the rest of the conveyor belt components are notsoluble. Once assembled, frangible tab 1845, or the junction betweenfrangible tab 1845 and first link 1815, may be dissolved away using asolution. Those having ordinary skill in the art will recognize otherpossible ways in which a tab can be rendered frangible.

In some embodiments, the mating surface of a frangible tab attached to afirst link may be curved to mate with a corresponding surface of asecond link. FIG. 26 illustrates an alternative shape for a frangibletab. Specifically, FIG. 26 shows a first link 2315 and a second link2320. First link 2315 may include a first rod receiving aperture 2335and second link 2320 may include a second aperture 2340. First link 2315may include a frangible tab 2345, having a first mating surface 2380,which may be configured to abut a second mating surface 2385 of secondlink 2320. As shown in FIG. 26, first mating surface 2380 and secondmating surface 2385 may be curved.

The curvature of the mating surfaces may facilitate alignment in avertical direction. For example, the concave curvature of first matingsurface 2380 may cradle second mating surface 2385 of second link 2320,preventing undesired vertical shifting of second link 2320 relative tofirst link 2315 during assembly.

In some embodiments, frangible alignment features may be provided thatmay be broken off by relative rotation of the pitches rather thanlongitudinal translation of the pitches with respect to one another. Forexample, in some embodiments, a U-shaped receiving member may bedisposed on a first link and a frangible tab may be orientedlongitudinally on a second link, where the receiving member may beconfigured to receive the frangible tab upon longitudinal translation ofthe second link into engagement with the first link. The frangible taband the receiving member may have mating surfaces that, when abutted,result in the alignment of a first rod receiving aperture on the firstlink with a second rod receiving aperture on the second link. Aconnecting rod may be inserted through the aligned apertures to assemblethe pitches of the conveyor belt. Once the rod has been inserted, thepitches may be rotated relative to one another to snap off the frangibletab.

FIG. 27 illustrates an embodiment including a frangible alignmentfeature. FIG. 27 shows a modular conveyor belt 2400, which may include afirst pitch 2405 and a second pitch 2410. First pitch 2405 may include afirst link 2415 and second pitch 2410 may include a second link 2420configured to be longitudinally aligned along a longitudinal axis 2425.First link 2415 and second link 2420 may be brought into engagement, forexample, by translating second link 2420 in a longitudinal directionindicated by arrow 2430. First link 2415 may include a first rodreceiving aperture 2435 and second link 2420 may include a second rodreceiving aperture 2440.

As shown in FIG. 27, first link 2415 may include a receiving member 2445disposed at a predetermined distance from first rod receiving aperture2435. Receiving member 2445 may be configured to receive alongitudinally oriented frangible tab 2450 extending from a surface ofsecond link 2420. When frangible tab 2450 is received within receivingmember 2445, first rod receiving aperture 2435 may be substantiallyaligned with second rod receiving aperture 2440 to form a rod receivingpath. The step of bringing second link 2420 into engagement with firstlink 2415 may be executed, for example, by longitudinally translating inthe direction of arrow 2430. The action associated with this first stepis further labeled “1” in FIG. 27. When apertures 2435 and 2440 aresubstantially aligned, a connecting rod 2455 may be inserted throughapertures 2435 and 2440. This second step of inserting connecting rod2455 is illustrated in FIG. 27 with an arrow labeled “2” in FIG. 27.Once frangible tab 2450 is received within receiving member 2445 andconnecting rod 2455 is inserted through apertures 2435 and 2440,frangible tab 2450 may be broken off by rotating second link 2420relative to first link 2415. Frangible tab 2450 may be retained withinreceiving member 2445 while the rest of second link 2420 is rotatedrelative to first link 2415, thereby causing frangible tab 2450 to bebroken off. This third step is illustrated by an arrow labeled “3” inFIG. 27.

Receiving member 2445 may include a first mating surface 2480, which maybe located a predetermined distance from first rod receiving aperture2435. Frangible tab 2450 may include a second mating surface 2475, whichmay be located a predetermined distance from second rod receivingaperture. For clearer illustration, reference may be made to a secondfrangible tab 2482, having a mating surface 2485.

In some embodiments, receiving member 2445 may include a substantiallyU-shaped protrusion extending from a surface of first link 2415.Accordingly, the U-shape may be configured to align second link 2420relative to first link 2415 in both vertical and longitudinal directionswhen frangible tab 2450 is received within receiving member 2445.Frangible tab 2450 may be maintained in vertical alignment with aperture2435 by a lower mating surface 2490 and an upper mating surface 2495,which may restrict the vertical movement of frangible tab 2450 whenreceived within receiving member 2445. The amount of play betweenfrangible tab 2450 and lower and upper mating surfaces 2490 and 2495 mayvary. In some cases the fit between these components may be relativelysnug, like a press-fit. In such cases, frangible tab 2450 may beretained within receiving member 2445 when broken off. In other cases,the fit of frangible tab 2450 within receiving member 2445 may berelatively loose, while still limiting the movement of frangible tab inorder to maintain alignment of apertures 2435 and 2440.

Frangible tab 2445 may be rendered frangible by any suitable means. Insome embodiments, the junction between frangible tab 2445 and secondlink 2420 may be weakened in some way. For example, in some embodiments,this junction may be perforated. In other embodiments, this junction maysimply be a thinner region of material. In still other embodiments, thisjunction may be both thinner and perforated. Alternatively, in someembodiments at least a portion of frangible tab 2445 may be soluble in asolution in which the rest of the conveyor belt components are notsoluble. Once assembled, frangible tab 2445, or the junction betweenfrangible tab 2445 and second link 2420, may be dissolved away using asolution. Those having ordinary skill in the art will recognize otherpossible ways in which a tab can be rendered frangible.

FIG. 28 illustrates an exemplary finger style conveyor belt 2800embodiment including alignment features. Conveyor belt 2800 may includea first pitch including a first link 2805 and a second pitch including asecond link 2810. The first pitch including first link 2805 and thesecond pitch including second link 2810 may be joined by a connectingrod 2815. First link 2805 may include a central transverse rib 2820.First link 2805 may further include at least one finger-like, forwardextending link leg 2825 extending from transverse rib 2820 in a forwarddirection, and at least one finger-like, rearward extending link leg2830 extending from transverse rib 2820 in a rearward direction. Secondlink 2810 may include a central transverse rib 2835. Second link 2810may further include at least one finger-like, forward extending link leg2840 and at least one finger-like, rearward extending link leg 2845.

Forward extending link leg 2850 of first link 2805 may include a firstrod receiving aperture 2850 extending through leg 2850 of first link2805, and rearward extending link leg 2845 may include a second rodreceiving aperture 2855. Apertures 2850 and 2855, when aligned, form arod receiving path, through which connecting rod 2815 may be inserted toattach first link 2805 and 2810. It shall be noted that, in someembodiments, transverse rib 2820 may be disposed between adjacentconnecting rods 2815, as is typical for a finger style belt.

In order to facilitate alignment of apertures 2850 and 2855, in someembodiments, first link 2805 and/or second link 2810 may include one ormore alignment features. For example, in some embodiments, forwardextending link leg 2825 of first link 2805 and/or rearward extendinglink leg 2845 of second link 2810 may include one or more shouldersforming mating surfaces that may be configured to abut one or moreportions of the adjacent link. Such shoulders could, for example, servesimilar purposes as cylindrical protrusions and/or wedge shapedprotrusions discussed above.

As shown in FIG. 28, first link 2805 may include a first mating surface2860, which may be configured to abut a second mating surface 2865 ofrearward extending leg 2845 of second link 2810. First mating surface2860 may be disposed proximate first rod receiving aperture 2850 andsecond mating surface 2865 may be disposed proximate second rodreceiving aperture 2855. In some embodiments, first mating surface 2860may be substantially planar. In other embodiments, first mating surface2860 may be curved or rounded, as shown in FIG. 28. In addition,although second mating surface 2865 is shown in FIG. 28 as beingsubstantially planar, in some embodiments, second mating surface 2865may be curved. For example, second mating surface 2865 may be curved tomate with curved first mating surface 2860. In some embodiments, firstmating surface 2860 may at least partially surround first rod receivingaperture 2850. For example, as shown in FIG. 28, first mating surface2860 may be substantially concentric with first rod receiving aperture2850. Curved mating surfaces may enable rotation of first link 2805 andsecond link 2810 relative to one another in a manner similar to otherembodiments discussed above.

Second mating surface 2865 may be formed by a shoulder that extends, forexample, less than 1 mm away from the surface of link leg 2845. Inaddition, link leg 2845 may also include a second shoulder forming athird contact surface 2870, which may be configured to abut a contactsurface 2875 of first link 2805, as shown in FIG. 28.

FIG. 29 illustrates a plan view of the embodiment shown in FIG. 28.

FIG. 30 illustrates an alternative embodiment similar to the embodimentshown in FIGS. 29 and 30. The embodiment shown in FIG. 30 includesadditional shoulders forming additional contact surfaces 2880 and 2885on forward extending link legs 2825 and 2887, which may be configured toabut a contact surface 2890 of rearward extending link leg 2845. Linkleg 2825 may also include a shoulder forming a further contact surface2895, which may be configured to abut a contact surface of a laterallyadjacent link.

FIG. 31 shows a further alternative embodiment, wherein only rearwardextending link legs include a single-sided contact surface 3100configured to abut first contact surface 2860 of first link 2805. FIG.32 also shows an asymmetrical configuration, wherein both rearwardextending link legs of second link 2810 and forward extending link legsof first link 2805 may include shoulders forming contact surfaces, 3100and 3105, respectively. Further, first link 2805 may also include afurther contact surface 3110 for abutting laterally adjacent links. Itshould be understood that, in accordance with the embodiments shown inFIGS. 28-32, contact surfaces may be provided in longitudinally and/orlaterally symmetrical or asymmetrical configurations.

The alignment features discussed herein may be used in many differenttypes of conveyor belts and may be combined with other technologiesintended to simplify the manufacturing of conveyor belts. For example,the rod retaining features mentioned above may be combined with the rodreceiving aperture alignment features to both ease proper aligning ofrod receiving apertures and insertion of the rod and, further, securelyretain the connecting rods once inserted.

While various embodiments of the current embodiments have beendescribed, the description is intended to be exemplary, rather thanlimiting and it will be apparent to those of ordinary skill in the artthat many more embodiments and implementations are possible that arewithin the scope of the current embodiments. Accordingly, the currentembodiments are not to be restricted except in light of the attachedclaims and their equivalents. Features of any embodiment described inthe present disclosure may be included in any other embodiment describedin the present disclosure. Also, various modifications and changes maybe made within the scope of the attached claims.

Further, in describing representative embodiments, the specification mayhave presented a method and/or process as a particular sequence ofsteps. However, to the extent that the method or process does not relyon the particular order of steps set forth herein, the method or processshould not be limited to the particular sequence of steps described. Asone of ordinary skill in the art would appreciate, other sequences ofsteps may be possible. Therefore, the particular order of the steps setforth in the specification should not be construed as limitations on theclaims. In addition, the claims directed to a method and/or processshould not be limited to the performance of their steps in the orderwritten, and one skilled in the art can readily appreciate that thesequences may be varied.

What is claimed is:
 1. A conveyor belt comprising: a first link having afirst protrusion extending a first distance from a first surface of thefirst link, wherein the first protrusion includes a first matingsurface, wherein the first mating surface is curved, wherein the firstprotrusion is disposed proximate a first rod receiving apertureextending through the first link; a second link having a secondprotrusion extending a second distance from a second surface of thesecond link, wherein the second protrusion includes a second matingsurface, wherein the second mating surface is curved, wherein the secondprotrusion is disposed proximate a second rod receiving apertureextending through the second link, wherein the first mating surface ofthe first protrusion receives and abuts the second mating surface of thesecond protrusion, the second link being restrained against movement inless than three orthogonal directions relative to the first link due toabutment of the first mating surface and the second mating surface, thefirst rod receiving aperture and the second rod receiving aperture beingaligned when the first mating surface abuts the second mating surface;and a connecting rod extending through the first rod receiving apertureof the first link and the second rod receiving aperture of the secondlink.
 2. The conveyor belt of claim 1, wherein the first link and thesecond link are configured to travel in a longitudinal direction,wherein the first mating surface has a first curvature and the secondmating surface has a second curvature, wherein the first curvaturecorresponds with the second curvature, and wherein the first rodreceiving aperture and the second rod receiving aperture are aligned inthe longitudinal direction and an additional direction due to abutmentof the first mating surface and the second mating surface, wherein theadditional direction is orthogonal to the longitudinal direction.
 3. Theconveyor belt of claim 1, wherein the second mating surface is annular,and wherein the first mating surface partially extends about the secondmating surface.
 4. The conveyor belt of claim 1, wherein the first linkand the second link are configured to travel in a longitudinaldirection, wherein the first protrusion is substantially aligned withthe first rod receiving aperture in the longitudinal direction, andwherein the second protrusion is substantially aligned with the secondrod receiving aperture in the longitudinal direction.
 5. The conveyorbelt of claim 1, wherein the second protrusion at least partiallysurrounds the second rod receiving aperture.
 6. The conveyor belt ofclaim 5, wherein the second protrusion continuously surrounds the secondrod receiving aperture.
 7. The conveyor belt of claim 1, wherein thefirst link is at least partially U-shaped to be at least partiallydefined by a first leg, a second leg, and a connecting portion betweenthe first leg and the second leg of the first link, wherein the firstleg and the second leg extend substantially in a longitudinal direction,wherein the connecting portion extends substantially in a transversedirection, and wherein the first mating surface substantially faces in avertical direction that is substantially orthogonal to the longitudinaldirection and the transverse direction.
 8. The conveyor belt of claim 1,wherein the first link and second link are made from a plastic material.9. A conveyor belt comprising: a first link that is at least partiallyU-shaped to be at least partially defined by a first leg, a second leg,and a first connecting portion extending between the first leg and thesecond leg of the first link, the first link further including a firstrod receiving aperture; a second link that is at least partiallyU-shaped to be at least partially defined by a third leg, a fourth leg,and a second connecting portion extending between the third leg and thefourth leg of the second link, the second link further including asecond rod receiving aperture; and a connecting rod extending throughthe first rod receiving aperture of the first link and the second rodreceiving aperture of the second link to connect the first link and thesecond link, wherein the first link and the second link are configuredfor movement in a longitudinal direction, wherein the first linkincludes a first protrusion extending from a first surface of the firstlink, wherein the first protrusion includes a first mating surface,wherein the first mating surface is curved, wherein the first matingsurface of the first protrusion receives and abuts a second surface ofthe second link to limit movement of the second link toward the firstlink in the longitudinal direction, and wherein the first mating surfaceof the first protrusion receives and abuts the second surface of thesecond link to align the first and second rod receiving apertures. 10.The conveyor belt of claim 9, wherein the second surface of the secondlink is defined on the second connecting portion of the second link. 11.The conveyor belt of claim 10, wherein the second surface is curved andhas a corresponding curvature to the first mating surface.
 12. Theconveyor belt of claim 11, wherein the first protrusion extends inwardlyfrom the first leg generally toward the second leg.
 13. The conveyorbelt of claim 9, wherein the second link includes a second protrusionthat extends from the second link, and wherein the second surface isdefined on the second protrusion.
 14. The conveyor belt of claim 13,wherein the second protrusion extends outwardly from the third leggenerally away from the fourth leg.
 15. The conveyor belt of claim 13,wherein the first protrusion is U-shaped.
 16. A conveyor beltcomprising: a first link having a first protrusion extending a firstdistance from a first surface of the first link, wherein the firstprotrusion includes a first mating surface, wherein the first matingsurface is curved, wherein the first protrusion is disposed proximate afirst rod receiving aperture extending through the first link; a secondlink having a second protrusion extending a second distance from asecond surface of the second link, wherein the second protrusionincludes a second mating surface, wherein the second mating surface iscurved, wherein the second protrusion is disposed proximate a second rodreceiving aperture extending through the second link, wherein the secondmating surface and the first mating surface abut to align the first rodreceiving aperture and the second rod receiving aperture, wherein thesecond mating surface and the first mating surface have correspondingcurvature, the second link being restrained against movement in lessthan three orthogonal directions relative to the first link due toabutment of the first mating surface and the second mating surface; anda connecting rod extending through the first rod receiving aperture ofthe first link and the second rod receiving aperture of the second link.17. The conveyor belt of claim 16, wherein the second mating surface isannular, and wherein the first mating surface partially extends aboutthe second mating surface.
 18. The conveyor belt of claim 16, whereinthe first link and the second link are configured to travel in alongitudinal direction, wherein the first protrusion is substantiallyaligned with the first rod receiving aperture in the longitudinaldirection, and wherein the second protrusion is substantially alignedwith the second rod receiving aperture in the longitudinal direction.19. The conveyor belt of claim 16, wherein the first link is at leastpartially U-shaped to be at least partially defined by a first leg, asecond leg, and a connecting portion between the first leg and thesecond leg of the first link, wherein the first leg and the second legextend substantially in a longitudinal direction, wherein the connectingportion extends substantially in a transverse direction, and wherein thefirst mating surface substantially faces in a vertical direction that issubstantially orthogonal to the longitudinal direction and thetransverse direction.
 20. The conveyor belt of claim 16, wherein thefirst link and second link are made from a plastic material.